Absorbent mats for food packaging

ABSTRACT

An absorbent mat includes top and bottom layers of thermoplastic material with absorbent media disposed therebetween. The top and bottom layers are bonded directly together, or to the absorbent media disposed therebetween, in spaced-apart bond sites. One or more perforations are formed as a result of bonding in the top and/or bottom layers in a peripheral portion of each bond. Each perforation is in communication with the absorbent media and provides a pathway through which liquid can pass. The top and bottom layers may be monolithic thermoplastic film with an aperture formed therethrough at each respective bond by stretching the multi-layer absorbent mat. One or more perforations are formed in the peripheral portion of each bond site thereof as a result of stretching. Each perforation is in communication with the absorbent media and provides a pathway through which liquid can pass into the absorbent media.

FIELD OF THE INVENTION

The present invention relates generally to packaging and, moreparticularly, to food packaging for improving the appearance of andprotecting various food products.

BACKGROUND OF THE INVENTION

Conventionally, meat, poultry, and other food products are displayed inindividual packages which include a supporting tray having an absorbentpad in the bottom thereof to absorb liquids (e.g., blood, water, saline,mixtures thereof, etc.) exuded from the food product. A transparentouter plastic wrapping is usually employed to cover and surround thefood product and tray to complete the package. There have been variousattempts to control liquids exuded from food products within packagingin order to extend the shelf-life of such food products. For exampleU.S. Pat. No. 4,382,507 discloses an absorbent pad disposed in a foodpackage for absorbing juices or other liquids exuded from food products.

Unfortunately, conventional food pads may not adequately absorb andretain exuded liquids from packaged food products. As a result, exudedliquids may accumulate in the tray and may migrate back into the foodproducts, resulting in spoilage and/or discoloration thereof. Inaddition, exuded liquids may spill or seep from the food package, whichmay lead to unsanitary conditions. U.S. Pat. No. 6,171,695 describes anabsorbent core bonded to a film top layer. The absorbent core includesmultiple layers of absorbent tissue paper calendared or embossedtogether. The laminate is held together by either mechanical forces orhydrogen bonding. The multiple layers absorb exuded liquids and expand.Unfortunately, the tissue paper layers may delaminate when wet and maynot hold moisture well under pressure.

U.S. Pat. No. 5,250,310 describes a bi-layer absorbent pad having anabsorbent core topped with a barrier layer of film or hydrophobicnonwoven material. Unfortunately, the absorbent pad is prone todelamination when wet. In addition, the absorbent media may break awayand contaminate a food product, which is unsanitary and undesirable.

U.S. Pat. No. 4,756,939 describes an absorbent pad having absorbentmedia enclosed within a barrier material, such as plastic film. The filmis perforated to allow liquids to seep in and be absorbed.Unfortunately, absorbent pads of this type may be slow to absorb liquidsand are typically available only in pre-determined sizes, which may leadto liquid under absorption within a food package. These pouch type padsmay contain superabsorbent material such as powder, granule, or fiber.The enclosed pouch is thought to be necessary to control the gel thatresults from the wetting of the superabsorbent material. The enclosedpouch also may expand or rupture when used for vacuum packaging ormodified atmosphere packaging. This rupture can contaminate the packageand, at times, can contaminate the production area.

Accordingly, there is a continuing need in the food packaging industryfor absorbent pads having high levels of liquid absorbency, that do notdelaminate easily when soaked in liquid, and that can be easilycustomized for various types, sizes, and shapes of food packages. Itwould be desirable to utilize superabsorbent materials in foodpackaging. Moreover, there is a need in food packaging for an absorbentpad that can absorb from its entire area, including the edges, and thatdoes not trap air when used for modified atmosphere packaging or vacuumprocessing.

SUMMARY OF THE INVENTION

In view of the above discussion, an improved absorbent mat and foodproduct package is provided that overcomes the limitations ofconventional food product packaging. According to embodiments of thepresent invention, a multi-layer absorbent mat for use within a foodproduct package includes top and bottom layers of thermoplastic materialand absorbent media disposed between the top and bottom layers. The topand bottom layers are thermally bonded directly together through theabsorbent media at multiple, spaced-apart sites. According to otherembodiments of the present invention, the top and bottom layers ofthermoplastic material may be thermally bonded to absorbent mediadisposed therebetween via binder fibers in the absorbent media.

Each bond site is defined by a bond portion where the top and bottomlayers are thermally bonded directly together through the absorbentmedia and a peripheral portion adjacent to the bond portion. One or moreruptures or perforations are formed as a result of thermal bonding in atleast one of the top or bottom layers in the peripheral portion of eachbond site. Each perforation is in communication with the absorbent mediaand provides a pathway through which liquid can pass from external tothe mat into the absorbent media.

According to embodiments of the present invention, the top and bottomlayers may be sealed (e.g., heat sealed, ultrasonically sealed, etc.)together along respective peripheral edges thereof to further containthe absorbent media.

According to embodiments of the present invention, either or both of thetop and bottom layers may be formed from nonwoven material or frommonolithic polymeric film. Each layer may have a thickness of betweenabout 0.3 mils and about 10.0 mils.

According to other embodiments of the present invention, a multi-layerabsorbent mat includes top and bottom layers of substantially liquidimpermeable (i.e., monolithic) thermoplastic film, and absorbent mediadisposed between the top and bottom layers. The top and bottom layersare thermally bonded directly together through the absorbent media atmultiple, spaced-apart bond sites. Each bond site is defined by a bondportion where the top and bottom layers are thermally bonded directlytogether through the absorbent media and a peripheral portion adjacentto the bond portion. An aperture is formed through the top and bottomlayers at each respective bond site by substantially evenly stretchingthe multi-layer absorbent mat via various devices and methodologies(e.g., bow rolls, tentering, ring rolls, interdigitating rolls spreaderrolls, etc.) by an amount between about one percent and about seventypercent (1%-70%) of a relaxed configuration thereof. One or moreruptures or perforations are formed in the peripheral portion of eachbond site thereof as a result of stretching. Each perforation is incommunication with the absorbent media and provides a pathway throughwhich liquid can pass from external to the mat into the absorbent media.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which form a part of the specification,illustrate embodiments of the present invention. The drawings anddescription together serve to fully explain the invention.

FIG. 1A is a perspective view of a multi-layer absorbent mat accordingto embodiments of the present invention.

FIG. 1B is an enlarged plan view of a bond site in the multi-layerabsorbent mat of FIG. 1A.

FIG. 1C is a cross-sectional view of the bond site of FIG. 1B takenalong lines 1C-1C.

FIG. 1D is a cross-sectional view of the bond site of FIG. 1B accordingto another embodiment of the present invention wherein the top andbottom layers are bonded to the absorbent media disposed therebetweenvia binder fibers in the absorbent media.

FIG. 2A is a perspective view of a multi-layer absorbent mat accordingto other embodiments of the present invention.

FIG. 2B is an enlarged plan view of a bond site in the multi-layerabsorbent mat of FIG. 2A.

FIG. 2C is a cross-sectional view of the bond site of FIG. 2B takenalong lines 2C-2C.

FIG. 3 is a graph illustrating the relationship of absorbency andstretch level for the multi-layer absorbent mat of FIGS. 2A-2C.

FIG. 4 is an exploded perspective view of a food product packageincorporating a multi-layer absorbent mat, according to embodiments ofthe present invention.

FIG. 5 is a perspective view of the food product package of FIG. 4including a food product and a surrounding plastic wrap.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now is described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. As usedherein, the term “nonwoven web”, refers to a web that has a structure ofindividual fibers or threads which are interlaid, but not in anyregular, repeating manner. Nonwoven webs may be formed by a variety ofprocesses, such as, for example, meltblowing processes, spunbondingprocesses and bonded carded web processes.

As used herein, the term “superabsorbent” refers to a special group ofpolymers that have the ability to absorb many times their own mass ofliquid. Superabsorbents are configured to swell very rapidly in liquid,but not dissolve.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as, for example, block,graft, random and alternating copolymers, terpolymers, etc., and blendsand modifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material. These configurations include, but arenot limited to, isotactic, syndiaotactic and random symmetries.

Referring to FIGS. 1A-1D, a multi-layer absorbent mat 10, according toembodiments of the present invention is illustrated. The illustrated mat10 includes top and bottom layers 12, 14 of substantially liquidimpermeable (i.e., monolithic) thermoplastic film, and absorbent media16 disposed between the top and bottom layers 12, 14. The top and bottomlayers 12, 14 are thermally bonded directly together through theabsorbent media 16 at multiple, spaced-apart bond sites 18, asillustrated in FIG. 1C. Alternatively, the top and bottom layers 12, 14are bonded to the absorbent media 16 at multiple, spaced-apart bondsites 18 via binder fibers in the absorbent media 16, as illustrated inFIG. 1D.

Each bond site 18 is defined by a bond portion 20 where the top andbottom layers 12, 14 are thermally bonded directly together through theabsorbent media 16 and a peripheral portion 22 adjacent to the bondportion 20. Fibers within the absorbent media 16 typically protrude fromthe top and bottom layers 12, 14 at the bond portion 20. One or moreruptures or perforations 24 are typically formed in at least one of thetop or bottom layers 12, 14 in the peripheral portion 22, as a result ofthermal bonding. Each perforation 24 is in communication with theabsorbent media 16 and provides a pathway through which liquid can passfrom external to the mat 10 into the absorbent media 16. An enlargedbond site 18 is illustrated in FIGS. 1B-1C and illustrates perforations24 formed in the bond peripheral portion 22.

The top and bottom layers 12, 14 are thermally bonded together atmultiple, spaced-apart locations or sites. However, other attachmentmethods may be utilized including, but not limited to, ultrasonicbonding, mechanical bonding, or other attachment means or combinationsof these attachment means as are known in the art. Moreover, the bondsites 18 may have various configurations and patterns. The total bondarea (i.e., the total area of all bonds) is preferably between aboutfive percent and about fifty percent (5%-50%) of the area of the top andbottom layers 12, 14, and more preferably between about ten percent andabout twenty five percent (10%-25%) of the area of the top and bottomlayers 12, 14. According to embodiments of the present invention, thetop and bottom layers 12, 14 may be sealed (e.g., heat sealed,ultrasonically sealed, etc.) together along respective peripheral edges12 a, 14 a thereof to further contain the absorbent media 16.

Thermal bonding is performed using sufficient force to bond the toplayer 12 through to the bottom layer 14. The bonding may be enhanced bythe incorporation of compatible thermoplastic fiber(s) into theabsorbent media 16. When thick or heavy absorbent media 16 is utilized,this may be necessary to ensure adequate bonding. The force isdetermined in individual cases depending on the nature of the absorbentmedia 16. The absorbent media may or may not participate in the thermalbonding; however, when fibers in the absorbent media 16 do participate,the bonding is typically more secure. Each bond site forms a visibledeformation of the structure even when the top and bottom layers arebonded to the absorbent media in lieu of each other. Thermal bonding maybe performed using an engraved roll over a smooth roll, or matchedengraved rolls, as would be understood by those skilled in the art ofthermal bonding.

Multiple spaced-apart bonding as illustrated in FIG. 1A can help preventcrushing or compressing of the absorbent media 16. Compression canreduce the void volume of the absorbent media 16 and limit the swellingof super-absorbent polymers in the absorbent media 16. The spaced-apartthermal bond sites 18 also reduce the damage to the absorbent capacitythat may occur when adhesives are used.

The absorbent media 16 may be manufactured from a wide variety ofliquid-absorbent materials including, but not limited to, wood pulp,creped cellulose wadding, meltblown polymers including coform, nonwovenfabric structures such as thermal bond or resin bond that containabsorbent fiber or superabsorbent particles or fibers, chemicallystiffened, modified or cross-linked cellulosic fibers, tissue includingtissue wraps and tissue laminates, absorbent foams, absorbent sponges,super-absorbent polymers, absorbent gelling materials, or any equivalentmaterial or combinations of materials. Exemplary absorbent media aredisclosed in U.S. Pat. Nos. 5,260,345; 5,268,224; and 5,628,097, each ofwhich is incorporated herein by reference in its entirety.

The absorbent media 16 may include tissue, tissue containingsuper-absorbent polymer, air-laid pulp, air-laid pulp withsuper-absorbent fiber or powder, absorbent nonwovens, or foams. Suitableair-laid pulps are available from Concert Industries and from Fort JamesCorporation. The use of air-laid pulp with super-absorbent fiber ispreferred. The air-laid pulp material may be bonded with thermoplasticbinder fiber, or with sprayed, printed, or coated binder. Suitablegrades of air-laid pulp include Concert Industries' gradeEDT.150.105.AS1359, or EDT 160.101.BS1359. Additionally, the absorbentmedia 16 may include super-absorbent polymer(s) in the form of a fiber,powder, flake, particle, or granule, or other form.

Suitable absorbent nonwovens include needlepunched rayon or tencel,which are available from American Nonwovens, Columbus, Miss. Suitabletissues are available from Procter & Gamble and Cellutissue Corporation.Tissues may range from about ten grams per square meter to about sixtygrams per square meter (10-60 gsm). A suitable product is Grade 3141-33,20 gsm, single ply white ultra absorbent laminating core tissue fromInterlake.

If binder fibers are present in the absorbent media 16, the binderfibers and the top and bottom layers 12, 14 are preferably compatible tofacilitate thermal bonding. Coextruded materials such aspolypropylene/polyethylene, polyester/polyethylene, andpolyester/polypropylene fibers are preferred binder fibers. In theillustrated embodiment, the absorbent media 16 includes wood pulp 16 a,superabsorbent fibers 16 b and binder fibers 16 c.

According to embodiments of the present invention, the absorbent media16 has a liquid capacity of at least about ten grams of liquid per onegram of absorbent media (10 g/1 g). In addition, the absorbent media 16may include thermoplastic material that is compatible with thethermoplastic material of the top and bottom layers 12, 14. Thiscompatible material facilitates bonding between the top and bottomlayers 12, 14.

According to embodiments of the present invention, one or more of thetop and bottom layers 12, 14 may be formed from nonwoven material orfrom monolithic polymeric film. Each layer 12, 14 may have a thickness,for example, of between about 0.3 mils and about 10.0 mils. Exemplarynonwoven materials that may be utilized include spunbonded webs,meltblown webs, and/or bonded carded webs. Moreover, a nonwoven webaccording to embodiments of the present invention may include syntheticfibers (e.g., nylon, polyester, acrylic, polyolefin, polyethylene,polypropylene, modacrylic, polyvinyl chloride, polyvinylidene chloride,urethane, copolyether ester, copolyether amide, polyolefin, etc.),natural fibers (e.g., wood fibers, cotton fibers, etc.), or a blend ofsynthetic and natural fibers. A nonwoven web according to embodiments ofthe present invention may be made of fiber forming polymers such as, forexample, polyolefins. Exemplary polyolefins include one or more ofpolypropylene, polyethylene, ethylene copolymers, propylene copolymers,and butene copolymers.

An example of spunbonded fabric includes CELESTRA® brand spunbondedpolypropylene from BBA Corporation, or SOFTEX® brand coextrudedpolypropylene core polyethylene sheath spunbond. Polyethylene spunbondsuch as DALTEX® brand spunbond from Don & Low Corporation is also apreferred material.

If a nonwoven web is utilized, blends of thermoplastic fibers andnon-thermoplastic fibers may be utilized if the blended fabrics arecapable of being thermally bonded. If a high percentage ofnon-thermoplastic fiber is not present or if bond strength is lower thandesired, a bond improving additive such as a thermoplastic powderadhesive, or a binder fiber, may be added to the web.

Exemplary monolithic polymeric films include, but are not limited topolyethylene, polypropylene, polyolefin, nylon, polyester, acrylic,modacrylic, polyvinyl chloride, polyvinylidene chloride, urethane,copolyether ester, and copolyether amide. A thermoplastic mesh ornetting may also be used. Suitable plastic netting is available fromDelstar, Inc. as DELNET® brand netting, and from Smith & Nephew, Inc.,and Conwed, Inc. Additionally, formed perforated films may be used suchas the VISPORE® brand films from Tredegar, Inc.

Referring to FIGS. 2A-2C, a multi-layer absorbent mat 110, according toembodiments of the present invention is illustrated. The illustrated mat110 includes top and bottom layers 112, 114 of substantially liquidimpermeable (i.e., monolithic) thermoplastic film, and absorbent media116 disposed between the top and bottom layers 112, 114. The top andbottom layers 112, 114 are thermally bonded directly together throughthe absorbent media 16 at multiple, spaced-apart bond sites 118, asillustrated. Alternatively, the top and bottom layers 112, 114 arethermally bonded to the absorbent media 16 at multiple, spaced-apartbond sites 118, via binder fibers in the absorbent media 16.

Each bond site 118 is defined by a bond portion 120 where the top andbottom layers 112, 114 are thermally bonded directly together throughthe absorbent media 116 and a peripheral portion 122 adjacent to thebond portion 120. However, other attachment methods may be utilizedincluding, but not limited to, ultrasonic bonding, mechanical bonding,or other attachment means or combinations of these attachment means asare known in the art. The total bond area (i.e., the total area of allbonds) is preferably between about five percent and about fifty percent(5%-50%) of the area of the top and bottom layers 112, 114, and morepreferably between about ten percent and about twenty five percent(10%-25%) of the area of the top and bottom layers 112, 114. Accordingto embodiments of the present invention, the top and bottom layers 112,114 may be sealed (e.g., heat sealed, ultrasonically sealed, etc.)together along respective peripheral edges 112 a, 114 a thereof tofurther contain the absorbent media 116.

Thermal bonding is performed using sufficient force to bond the toplayer 112 through to the bottom layer 114. The bonding may be enhancedby the incorporation of compatible thermoplastic fiber(s) into theabsorbent media 116. When thick or heavy absorbent media 116 isutilized, this may be necessary to ensure adequate bonding. The force isdetermined in individual cases depending on the nature of the absorbentmedia 116. The absorbent media may or may not participate in the thermalbonding; however, when fibers in the absorbent media 16 do participate,the bonding is typically more secure.

Thermal bonding may be performed using various techniques, includingthose described above with respect to the mat 10 of FIGS. 1A-1C. The topand bottom layers 112, 114 may be formed from various monolithicpolymeric films as described above with respect to the mat of FIGS.1A-1C. Each layer 112, 114 may have a thickness, for example, of betweenabout 0.3 mils and about 10.0 mils. In addition, the absorbent media mayinclude various materials as described above with respect to the mat ofFIGS. 1A-1C.

Once the top and bottom layers 112, 114 are bonded together, an aperture130 is formed through the top and bottom layers at each respective bondsite 118 by stretching the multi-layer absorbent mat 110 by an amountbetween about one percent and about seventy percent (1%-70%) of arelaxed configuration thereof. According to embodiments of the presentinvention, a multi-layer absorbent mat 110 may be substantially evenlystretched by passing the mat 100 through interdigitated rolls. Anexemplary method using interdigitated rolls is described in U.S. Pat.No. 5,628,097 which is incorporated herein by reference in its entirety.Other methods of stretching include, but are not limited to, stretchingvia bow rolls and tenter framing. Stretching may be performed in one ormore directions, and either substantially simultaneously orsequentially. Other exemplary stretching processes are disclosed in U.S.Pat. Nos. 4,368,565 and 4,116,892, each of which is incorporated hereinby reference in its entirety.

An enlarged bond site 118 is illustrated in FIGS. 2B-2C and illustratesan aperture 130 formed at a bond site 118. One or more ruptures orperforations 124 are formed in the peripheral portion 122 of each bondsite thereof, as illustrated in FIGS. 2B-2C. Each perforation 124 is incommunication with the absorbent media 116 and provides a pathwaythrough which liquid can pass from external to the mat 110 into theabsorbent media 116. As illustrated in FIGS. 2A-2B, various fibers fromthe absorbent media 116 may protrude through the perforations 124 formedin the peripheral portion 122 of each bond site 118.

Applicant has unexpectedly discovered that absorbency of a mat accordingto embodiments of the present invention increases with stretch level, asillustrated in FIG. 3. As a result, a mat according to embodiments ofthe present invention can be stretched so as to fully cover the tray ofa food product package and so as to have increased absorbency over anunstretched mat.

Referring now to FIG. 4, a food product package 200, within whichmulti-layer absorbent mats 10, 110, according to embodiments of thepresent invention, may be utilized, is illustrated. The illustrated foodproduct package 200 includes a tray 210 and a multi-layer absorbent mat10, 110. The tray 210 has a bottom wall 214 and a raised rim 215. Themulti-layer absorbent mat 10, 110 is disposed on the tray bottom wall214 and is configured to absorb liquids exuded from food products placedthereon via the perforations 24, 124 formed at each bond site 18, 118 asdescribed above. As illustrated in FIG. 5, an overwrap of flexible filmmaterial 217 covers a food product FP placed on the mat 10, 110 withinthe tray 210.

Unlike conventional food product packages, mats according to embodimentsof the present invention can have their peripheral edges sealedtogether. As such, absorption of liquids from food products viaperforations 24, 124 is extremely efficient and effective.

Mats 10, 110 may be manufactured in a wide variety of sizes and shapes(e.g., rectangular, circular, oval, hourglass, “T”-shaped, asymmetric,etc.), and can be adapted to any type and shape of food product beingpackaged. The layers 12, 112 and 14, 114 need not be identical in shapeor composition. The layers 12, 112 and 14, 114 maintain separationbetween a food product FP and the absorbent media 16, 116. This preventscontamination of the food product FP with particles from the absorbentmedia and allows for easy separation of the food product from the mat 12without causing delamination of the mat 10, 110, even when frozen.

The following examples are provided in order to further illustratevarious embodiments of the invention and are not to be construed aslimiting the scope thereof.

EXAMPLE 1

A highly absorbent structure comprised of an airlaid nonwoven sandwichedbetween two monolithic films was produced. The individual film andairlaid layers were passed between a patterned calendar roll and asmooth anvil roll. The patterned calendar roll produced multiple spacedapart bond sites. The bond pattern coupled with temperature and pressureresulted in a structure where the two thermoplastic layers were bondedthrough the absorbent core. This airlaid was encapsulated between thebond site areas. Bonding temperature was 200° F. for both the patternedand smooth calendar rolls. Pressure in the calendar nip wasapproximately 600 psi. The airlaid nonwoven was produced by ConcertIndustries (style 130.2382) and had a basis weight of 130 gsm. Theairlaid was comprised of 30% super absorbent fiber, 16%polyethylene/polyester bicomponent fiber (sheath/core), and 64% woodpulp. The films were both 0.5 mil low density polyethylene (style FT220)embossed films manufactured by Filmtech. Gross absorbency in deionizedwater using a 1 minute dunk and a 1 minute drip is shown below inTable 1. TABLE 1 Absorbency in Absorbency in Weight Thickness DeionizedWater Deionized Water (gsm) (in) (g_(water)/g_(fabric)) (g/in²) 159.20.040 25.8 2.65

EXAMPLES 2-9

Highly absorbent porous structures comprised of an airlaid nonwovensandwiched between two monolithic films were produced. First, theindividual film and airlaid layers were passed between a patternedcalendar roll and a smooth anvil roll. The patterned calendar rollproduced multiple spaced apart bond sites. The bond pattern coupled withtemperature and pressure resulted in a structure where two thermoplasticlayers were bonded through the absorbent core. This airlaid wasencapsulated between the bond site areas. Bonding temperature was 200°F. for both the patterned and smooth calendar rolls. Pressure in thecalendar nip was approximately 600 psi. The airlaid nonwoven wasproduced by Concert Industries (style 130.2382) and had a basis weightof 130 gsm. The airlaid was comprised of 30% super absorbent fiber, 16%polyethylene/polyester bicomponent fiber (sheath/core), and 64% woodpulp. The films were both 0.5 mil low density polyethylene (style FT220)embossed films manufactured by Filmtech Corporation.

Following bonding, composites were then stretched differing amounts inthe cross direction ranging from 0.0% to 40.7%. Transverse directionextension resulted in the formation of small tears at the bond sites.The size of the rupture was dependent on the level of stretch. Theairlaid was still contained in the land area between the bond sites.Table 2 shows gross absorbency using a 1 minute dunk and one minute driptest protocol in deionized water as stretch level increased. TABLE 2Absorbency in Absorbency in Basis Weight Deionized Deionized Stretch w/ofilm Thickness Water Water Examples (%) (gsm) (in) (g/in²)(g_(water)/g_(fabric)) 1 0.0 159.2 0.040 2.65 25.8 2 5.5 140.6 0.0402.68 29.6 3 7.2 148.7 0.044 3.12 32.6 4 9.8 146.0 0.046 2.98 31.6 5 13.1139.2 0.045 2.74 30.6 6 17.3 132.7 0.046 3.05 35.6 7 24.8 126.4 0.0482.78 34.1 8 32.2 110.3 0.052 2.54 35.9 9 40.7 111.9 0.048 2.73 37.8

The initial composite was stretched incrementally and the gram/gramabsorbency was measured. FIG. 3 shows a steady increase in theabsorbency as the stretch is increased. The absorbency of the productsis often measured in saline solutions of from 0.05% to 1%. These salinelevels are seen in the fluids that leach from meat when packed for sale.The absorbency of the super-absorbent fibers is reduced by salinecontent and therefore the blend of cellulose fibers with super-absorbentfibers is used. Depending on the fluid to be absorbed, the compositionof the absorbent layer may be adjusted appropriately.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. The invention is defined by the followingclaims, with equivalents of the claims to be included therein.

1-30. (canceled)
 31. A multi-layer absorbent mat, comprising: top andbottom layers of monolithic thermoplastic film; and absorbent mediadisposed between the top and bottom layers; wherein the top and bottomlayers are thermally bonded directly together through the absorbentmedia at multiple, spaced-apart locations, wherein an aperture is formedthrough the top and bottom layers at each respective bond site bystretching the multi-layer absorbent mat by an amount between about onepercent and about seventy percent (1%-70%) of a relaxed configurationthereof, wherein one or more perforations are formed in at least one ofthe top or bottom layers in a peripheral portion of each aperture,wherein the perforations are in communication with the absorbent media,and wherein the absorbent media has a liquid capacity of at least aboutten grams of liquid per one gram of absorbent media.
 32. The multi-layerabsorbent mat of claim 31, wherein the top and bottom layers are sealedtogether along respective peripheral edges thereof.
 33. The multi-layerabsorbent mat of claim 31 wherein the top and bottom layers each have athickness of between about 0.3 mils and about 10.0 mils.
 34. Themulti-layer absorbent mat of claim 31, wherein at least one of the topand bottom layers comprise polyolefin.
 35. The multi-layer absorbent matof claim 31, wherein the absorbent media comprises material selectedfrom the group consisting of paper, nonwoven fabrics, super-absorbentpolymers, and foams.
 36. The multi-layer absorbent mat of claim 35,wherein super-absorbent polymers are in the form of fibers, powders,flakes, particles, or granules.
 37. The multi-layer absorbent mat ofclaim 31, wherein the thermoplastic film is selected from the groupconsisting of nylon film, polyester film, acrylic film, modacrylic film,polyvinyl chloride film, polyvinylidene chloride film, urethane film,copolyether ester film, and copolyether amide film. 38-53. (canceled)54. A food product package, comprising: a tray with a bottom wall and araised rim; a multi-layer absorbent mat disposed on the tray bottomwall, comprising: top and bottom layers of thermoplastic material; andabsorbent media disposed between the top and bottom layers, wherein theabsorbent media comprises binder fibers disposed therewithin; whereinthe top and bottom layers are thermally bonded to the absorbent mediavia the binder fibers at multiple, spaced-apart locations, wherein oneor more perforations are formed as a result of thermal bonding in atleast one of the top or bottom layers in a peripheral portion of eachbond, wherein the perforations are in communication with the absorbentmedia, and wherein the absorbent media has a liquid capacity of at leastabout ten grams of liquid per one gram of absorbent media.
 55. The foodproduct package of claim 54, wherein at least one of the top and bottomlayers comprises nonwoven material.
 56. The food product package ofclaim 54, wherein at least one of the top and bottom layers comprises amesh material
 57. The food product package of claim 54, wherein at leastone of the top and bottom layers comprises thermoplastic film
 58. Thefood product package of claim 54, wherein the top and bottom layers aresealed together along respective peripheral edges thereof.
 59. The foodproduct package of claim 54, wherein the top and bottom layers each havea thickness of between about 0.3 mils and about 10.0 mils.
 60. The foodproduct package of claim 54, wherein at least one of the top and bottomlayers comprise polyolefin.
 61. The food product package of claim 54,wherein the absorbent media comprises material selected from the groupconsisting of paper, nonwoven fabrics, super-absorbent polymers, foamsand cellulose.
 62. The food product package of claim 61, whereinsuper-absorbent polymers are in the form of fibers, powders, flakes,particles, or granules.
 63. The food product package of claim 55,wherein the nonwoven material comprises synthetic fibers.
 64. The foodproduct package of claim 63, wherein the synthetic fibers are single,bicomponent, or multicomponent in structure and comprise polymersselected from the group consisting of olefin fibers, nylon fibers,polyester fibers, copolyester fibers, viscose fibers, acrylic fibers,modacrylic fibers, polyvinyl chloride fibers, polyvinylidene chloridefibers, urethane fibers, copolyether ester fibers, and copolyether amidefibers.
 65. The food product package of claim 55, wherein the nonwovenmaterial comprises natural fibers.
 66. The food product package of claim65, wherein the natural fibers are selected from the group consisting ofwood fibers and cotton fibers.
 67. The food product package of claim 55,wherein the nonwoven thermoplastic material comprises a blend ofsynthetic and natural fibers.
 68. The food product package of claim 57,wherein the thermoplastic film is selected from the group consisting ofnylon film, polyester film, acrylic film, modacrylic film, polyvinylchloride film, polyvinylidene chloride film, urethane film, copolyetherester film, and copolyether amide film.
 69. The food product package ofclaim 54, further comprising an overwrap of flexible film material thatis configured to cover a food product placed on the multi-layerabsorbent mat within the tray.
 70. A food product package, comprising: atray with a bottom wall and a raised rim; a multi-layer absorbent matdisposed on the tray bottom wall, comprising: top and bottom layers ofmonolithic thermoplastic film; and absorbent media disposed between thetop and bottom layers; wherein the top and bottom layers are thermallybonded directly together through the absorbent media at multiple,spaced-apart locations, wherein an aperture is formed through the topand bottom layers at each respective bond site by stretching themulti-layer absorbent mat by an amount between about one percent andabout seventy percent (1%-70%) of a relaxed configuration thereof,wherein one or more perforations are formed in at least one of the topor bottom layers in a peripheral portion of each aperture, wherein theperforations are in communication with the absorbent media, and whereinthe absorbent media has a liquid capacity of at least about ten grams ofliquid per one gram of absorbent media.
 71. The food product package ofclaim 70, wherein the top and bottom layers are sealed together alongrespective peripheral edges thereof.
 72. The food product package ofclaim 70, wherein the top and bottom layers each have a thickness ofbetween about 0.3 mils and about 10.0 mils.
 73. The food product packageof claim 70, wherein at least one of the top and bottom layers comprisepolyolefin.
 74. The food product package of claim 70, wherein theabsorbent media comprises material selected from the group consisting ofpaper, nonwoven fabrics, super-absorbent polymers, and foams.
 75. Thefood product package of claim 74, wherein super-absorbent polymers arein the form of fibers, powders, flakes, particles, or granules.
 76. Thefood product package of claim 70, wherein the thermoplastic film isselected from the group consisting of nylon film, polyester film,acrylic film, modacrylic film, polyvinyl chloride film, polyvinylidenechloride film, urethane film, copolyether ester film, and copolyetheramide film.
 77. The food product package of claim 70, further comprisingan overwrap of flexible film material that is configured to cover a foodproduct placed on the multi-layer absorbent mat within the tray.